Bendable plug wire-to-spark plug connector

ABSTRACT

An electrical connector for conductively connecting two terminal end portions comprising a first terminal contacting portion at one end of the connector, a second terminal contacting portion at the other end of the connector, and a transition section connecting the first and second terminal contacting portions. The transition section includes a pair of spaced apart generally parallel bendable strap portions which normally maintain the terminal contacting portions in alignment but which may be bent to angularly displace the terminal contacting portions up to 90*. In a preferred form, the electrical connecting device serves to connect a spark plug to its secondary ignition cable and the transition section includes at least one, and preferably a plurality of angles therein.

United States Patent [191 Davis Nov. 11, 1975 Neal R. Davis, 916 NW. 14, Oklahoma City, Okla. 73106 [76] Inventor:

[22] Filed: Nov. 30, 1973 [21] Appl. No.: 420,688

[52] US. Cl 339/245; 339/223 S; 339/276 T [51] Int. Cl.- HOlR 13/12 [58] Field of Search 339/26, 223, 245, 276,

[56] References Cited UNITED STATES PATENTS 2.035.947 3/1936 Davis. Jr. 339/223 S 2.457.796 12/1968 White 113/119 2.989.724 6/1961 Woofter 339/223 R 3.047.832 7/1962 Deakin 113/119 3.242.458 3/1966 Raymond et a1. 339/223 S 3.243.763 3/1966 E1liott.... 339/223 S 3.246.284 4/1966 Farison 339/223 S 3.364.459 1/1968 Schiller 339/245 3.793.616 2/1974 Moehrkc 339/223 S Primary E.\'anzinerJoseph H. McGlynn Attorney, Agent, or Firm-Clarence A. OBrien; Harvey B. Jacobson [5 7 ABSTRACT An electrical connector for conductively connecting two terminal end portions comprising a first terminal contacting portion at one end of the connector, a second terminal contacting portion at the other end of the connector. and a transition section connecting the first and second terminal contacting portions. The transition section includes a pair of spaced apart generally parallel bendable strap portions which normally maintain the terminal contacting portions in alignment but which may be bent to angularly displace the terminal contacting portions up to 90. In a preferred form, the electrical connecting device serves to connect a spark plug to its secondary ignition cable and the transition section includes at least one, and preferably a plurality of angles therein.

5 Claims, 5 Drawing Figures US. Patent Nov. 11, 1975 3,918,789

Fig-3 4/ 5} l BENDABLE PLUG WIRE-TO-SPARK PLUG CONNECTOR The present invention relates to electrical connectors and, more particularly, to conductive connectors for joining terminal end portions whereby the terminals can be angularly displaced relative to each other without interrupting the conductive connection.

It is an object of the present invention to provide an electrical connector having sufficient flexibility built' therein to permit angular displacement between the terminal contacting end portions, yet with sufficient rigidity to hold its bent shape, and with sufficient strength to permit further bending to other angular configurations.

It is another object of this invention to provide an electrical connector including normally aligned electrical contact ferrules at opposite ends and including a transition section between the ferrules which has give points built therein to permit up to 90 angular displacement of the ferrules.

It is still another object of the present invention to provide such an electrical connector particularly adapted for connecting a spark plug terminal to its secondary ignition cable.

Other objects and advantages will become apparent from the following description and appended claims taken in conjunction with the accompanying drawings.

FIG. 1 is a perspective view of the connector of the present invention.

FIG.- 2 is a perspective view of the connector of FIG. 1 bent along the transition section to angularly displace the terminal contacting ferrules.

FIG. 3 is a plan view of the blank from which the connector of FIG. 1 can be formed.

FIG. 4 is a plan view of the connector of FIG. 1.

FIG. 5 is a side eleaational view of the connector of FIG. 1.

Referring first to FIG. 1 there is designated generally at the electrical connector of the present invention. In one broad form the connector consists of two terminal contacting ferrules at opposite ends'of the connector joined by a transition section therebetween. In a preferred embodiment of the connector, one ferrule is adapted for contacting the terminal of a spark plug and the other ferrule is adapted for contacting the cable of the secondary ignition wire to the spark plug. However, it will be appreciated, that the terminal contacting ferrules may be adapted to make contact with any type of electrical terminal, wire or any electrical conducting device or material.

In the embodiment of FIG. 1, connector 10 consists of a spark plug terminal contacting ferrule 12 at one end, a secondary ignition cable contacting ferrule 14 at the other end and a transition section 16 connecting ferrules 12 and 14. Spark plug terminal ferrule 12 is adapted to fit over the generally cylindrical spark plug terminal and is formed of a generally tubular body 18 including a longitudinally extending split portion 20. The ferrule is split to take advantage of the generally resilient nature of the metal from which body 18 is formed whereby the body can spring engage the spark plug terminal. Axially spaced along body 18 are a plurality of corrugations or circumferential ribs 22 to stiffen or rigidify body 18 and to cooperate with corresponding ribs which may be present on the terminal post of the spark plug.

Secondary ignition cable ferrule 14 is generally U- shaped and includes a pair of diverging walls 24, 26 joining together at the trough 28 of the U. Walls 24, 26 are adapted to be crimped together over a secondary ignition cable received in the trough 28 to increase the pull-out strength of the connector. Projecting rearwardly and upwardly from trough 28 is a contact 30 which'is preferably'struck from the trough forming material. Contact 30 is V-shaped in order that the point of the V can puncture the insulation of the secondary ignition cable to make electrical contact with the current carrying wire therein.

Extending between and integral with ferrules 12 and 14 and conductively joining the ferrules in axial alignment is a transition section 16 consisting of two spaced apart, generally parallel strap members 32 and 34. Each strap member consists of three distinct portions, each portion angularly displaced from the other portions. The respective portions for strap 32 are denoted as 32a, 32b and 320 and for strap 34 as 34a, 34b and 340. Portions 32a and 34a converge as they extend rearwardly from diametrically opposed sides of tubular body 18 defining angles A, and A between body 18 and portions 32a and 34a, respectively. Portions 32b and 34b continue rearwardly from portions 32a and 34a in generally parallel confronting relation defining angles B, and B between portions 32a and 32b and portions 34a and 34b, respectively. Portions 32c and 34c diverge from portions 32band 34b into contact with the walls 24 and 26 of ferrule 14 defining angles C, and C between portions 32band 32 c and portions 34b'and 340, respectively. In addition, angles D, and D are defined between portion 320 and wall 24 and portion 340 and wall 26,respectively.

Angles A,, A,, B,, 13 C,, C D, and D constitute give points in transition section 16 which confer complete flexibility on connector 10 without the need for add-ons, modifications or the use of excessive pressure to'angularly displace the ferrules l2 and 14, as shown in FIG. 2. By virtue of these give points flexible movement may be achieved both back and'forth and side to side without immediate shearing or tearing of the metal. Moveover, the angles are not only the knee action in the straps conferring flexibility when the connector is bent, they are also the locking devices preventing collapse of the connector when pressure is applied to either end of the connector tending to axially push one ferrule into the other. The angles A,, A B,, B C,, C D, and D acting in conjunction with portions a, b and c of the respective straps, furnish wedging support acting against the application of such axial pressure.

A particular advantage of the connector of the present invention is that by virtue of its configuration it can be bent numerous times in varying directions without breaking or shearing and without setting up additional resistance to the flow of electricity. Moreover, even if one of straps 32 or 34 happens to break, the other strap remains intact to make conductive contact and to permit further bending. it is noteworthy that angles A,, A 13,, B C,, C D, and D although denoted as angles, preferably do not form a sharp corner at the intersection of the angle forming walls. Rather, the intersections are formed with a small curvature or radius to further reduce the tendency of the connector to shear or break.

FIG. 3 illustrates the blank 50 from which the connector can be formed. Blank 50 consists of two transversely extending, spaced apart generally rectangular zones 52 and 54 joined by longitudinally extending, spaced apart generally rectangular strap portions 56 and 58, the zones and strap portions defining an opening 60 therebetween. Zone 54 includes a laterally upward struck V-shaped contact 62 formed therein. To form blank 50 into connector 10, zone 52 is rolled until its upper and lower margins'64 and 66 are closely adjacent to form split portion of tubular body 18. At the same time, zone 54 is bent to its diverging wall U-shape with contact 62 in the trough of the U. When blank 50 is properly dimensioned, upon rolling and bending zones 52 and 54, strap portions 56 and 58 will form a generally parallel, confronting strap transition section between zones 52 and 54. Thereafter, it is a simple matter to bend strap portions 56 and 58 to include the desired angles, such as are shown in the accompanying figures in connection with connector 10. It will be appreciated that while the particular bends and configuration of strap members 32 and 34 of connector 10 constitute the preferred embodiment of the present invention, the transition section 16 may include any variety of combination of angles and strap member configurations suitable for forming a readily bendable, but difficult-to-break, connecting link between terminal contact ferrules.

While the present invention has been described with reference to particular embodiments thereof, it will be understood that numerous modifications can be made by those skilled in the art withoutactually departing from the scope of the invention. Accordingly, all modifications and equivalents may be resorted to which fall within the scope of the invention as claimed.

What is claimed as new is as follows:

1. An electrical connector of unitary construction for.

conductively connecting two terminal end portions, comprising:

a. a first terminal contacting portion at one end of said connector, said first terminal contacting portion comprising a splittubular ferrule including at least one circumferential rib extending outwardly therefrom;

b. a second terminal contacting portion at the other end of said connector comprising a generally U- shaped ferrule and means integral with said U- shape to make electricalcontact with an electrical cable, whereby the walls of said U-shaped ferrule are adapted to be crimped onto said cable, said sec ond terminal contacting portion normally aligned with said first terminal contacting portion and adapted to be angularly displaced therefrom; and c. a transistion section connecting said first and sec ond terminal contacting portions, said transition section comprising a pair of elongated, mutually,

independent, spaced apart, generally parallel,

bendable strap portions including at least one pre' t formed transverse bend in each strap portion, said strap portions including first and second pairs of corresponding opposite end portions, said first pair of corresponding end portion secured to andex tending from diametrically oppositeportions of;

said first terminal contacting portion and said second pair of corresponding end portions secured to said walls of said U-shaped second terminal contacting portion, said strap portions being free of connection with each other intermediate said pairs of corresponding opposite end portions and includ; ing segments which converge toward and diverge away from, and which substantially parallel, each 4. A connector, as claimed in claim 3, wherein said first terminal contacting portion is a spark plug contacting portionand said second terminal contacting portion is a secondary ignition cable contacting portion.

5. A connector, as claimed in claim 3, wherein said means to make electrical contact comprises an upstanding V-shaped contact extending upwardly into I said U from the trough thereof. 

1. An electrical connector of unitary construction for conductively connecting two terminal end portions, comprising: a. a first terminal contacting portion at one end of said connector, said first terminal contacting portion comprising a split tubular ferrule including at least one circumferential rib extending outwardly therefrom; b. a second terminal contacting portion at the other end of said connector comprising a generally U-shaped ferrule and means integral with said U-shape to make electrical contact with an electrical cable, whereby the walls of said U-shaped ferrule are adapted to be crimped onto said cable, said second terminal contacting portion normally aligned with said first terminal contacting portion and adapted to be angularly displaced therefrom; and c. a transistion section connecting said first and second terminal contacting portions, said transition section comprising a pair of elongated, mutually independent, spaced apart, generally parallel, bendable strap portions including at least one preformed transverse bend in each strap portion, said strap portions including first and second pairs of corresponding opposite end portions, said first pair of corresponding end portion secured to and extending from diametrically opposite portions of said first terminal contacting portion and said second pair of corresponding end portions secured to said walls of said U-shaped second terminal contacting portion, said strap portions being free of connection with each other intermediate said Pairs of corresponding opposite end portions and including segments which converge toward and diverge away from, and which substantially parallel, each other between said ferrules.
 2. A connector, as claimed in claim 1, wherein said preformed bend is a preformed angle.
 3. A connector, as claimed in claim 1, wherein said parallel segments are intermediate the converging and diverging segments.
 4. A connector, as claimed in claim 3, wherein said first terminal contacting portion is a spark plug contacting portion and said second terminal contacting portion is a secondary ignition cable contacting portion.
 5. A connector, as claimed in claim 3, wherein said means to make electrical contact comprises an upstanding V-shaped contact extending upwardly into said U from the trough thereof. 